Material moving apparatus

ABSTRACT

Described herein is a material moving apparatus that includes a chamber into which a compressible material is introduced. The chamber includes an input opening for receiving the material, a discharge opening and a sealing mechanism to prevent flow of air or other gasses between the input opening and the discharge opening. In one embodiment, the material moving apparatus can be used to introduce compressible biomass into a gasification reactor.

This application claims the benefit of U.S. Provisional Application No. 61/482,748, filed May 5, 2011, the contents of which are herein incorporated by reference.

BACKGROUND OF THE INVENTION

Gasification is an endothermic process that converts carbon based materials, such as coal, petroleum, biofuel, or biomass into a combustible gas by the partial or incomplete combustion of the raw material at high temperatures (i.e., between about 1000° C. to 5000° C.) with a controlled amount of oxygen and/or steam. The process takes place in a device called a gasifier or a gasification reactor, which can range in size, shape, and design. Instead of the biomass burning quickly, the material in the gasifier has limited oxygen such that the combustion occurs in multiple separate stages. The lack of oxygen and slow burn rate encourage the fuel to release combustible gases that include carbon monoxide (CO), hydrogen (H₂), methane (CH₄) and trace amounts of higher hydrocarbons, for example, ethane (C₂H₄) and ethane (C₂H₆). This combustible mixture can also be called producer gas, which can be used to run internal combustion engines (both compression and spark ignition), as substitute for furnace oil and to produce methanol—which is useful both as fuel for heat engines as well as chemical feedstock for industries. However, in order for the gasification process to be effective, only a limited amount of oxygen can be introduced into the reactor.

Although gasification of fossil fuels is currently widely used on an industrial scale to generate electricity, it is desirable to use other organic materials, such as wood, biomass, or even plastic waste on an industrial scale for energy production. However, despite the interest in commercialization of biomass gasification, the known processes are, for the most part, not economically viable.

SUMMARY OF THE INVENTION

Described herein is a material moving apparatus. The apparatus includes a chamber having an input opening for receiving a compressible raw material and a discharge opening. A ram is mounted within the chamber and configured to compress the raw material and urge the compressed material towards the discharge opening of the chamber. A valve is located downstream of the discharge opening and is configured to control the pressure under which the material is compressed by controlling movement of the compressed material out of the discharge opening of the chamber. In one embodiment, the material is compressed to form a compressed material that is impermeable to air and/or other gasses. For example, the material can be compressed under a working pressure of at least about 5 psi and up to about 1000 psi.

In one embodiment, the material moving apparatus includes a downstream receptacle, for example, a discharge pipe operably connecting the material moving apparatus to a gasification reactor. In one embodiment, the gasification reactor operates under a vacuum of at least about 0.5 psi and up to about 5.0 psi. Advantageously, the compressed material is substantially air-impermeable, thereby preventing movement of air and/or other gasses from the pumping chamber into the downstream recepticle.

In one embodiment, the compressible material comprises biomass that can be gasified in a gasification reactor. Examples of biomass include, for example, bio-solids, including, saw dust, yard trimmings, compost, wood chips, straw, grass, corn cobs, and corn stover; garbage or waste material, including, bottles, cans, clothing, disposables, food packaging, and food scraps; paper materials, including, newspapers, magazines, cardboard, office paper, and paper bags; plastic materials, including milk jugs and other storage containers; and mixtures and combinations thereof.

In one embodiment, a single chamber functions as both a pumping chamber and a sealing chamber. In another embodiment, the material moving apparatus includes a sealing chamber that is distinct from the pumping chamber. For example, it may be desirable to have a separate sealing chamber that defines an enclosure with a different shape and/or size is than the enclosure defined by the pumping chamber to prevent back-flow of the compressed material into the pumping chamber and/or input receptacle of the material moving apparatus. In one embodiment, the pumping chamber defines a first enclosure having a first cross-sectional dimension and the sealing chamber defines a second enclosure with a second cross-sectional dimension, wherein the cross-sectional dimension of the second enclosure defined by the sealing chamber is greater than the cross-sectional dimension of the pumping chamber. In another embodiment, the pumping chamber defines a first enclosure having a first cross sectional shape and the sealing chamber defines a second enclosure having a second cross-sectional shape, wherein the cross-sectional shape of the sealing chamber is different than the cross-sectional shape of the pumping chamber.

A variety of valves can be used in connection with the material moving apparatus described herein. In one embodiment, the valve comprises a check valve, such as a flap valve.

A method for moving a compressible material is also described.

This summary is an overview of some of the teachings of the present application and is not intended to be an exclusive or exhaustive treatment of the present subject matter. Further details are found in the detailed description and appended claims. Other aspects will be apparent to persons skilled in the art upon reading and understanding the following detailed description and viewing the drawings that form a part thereof, each of which is not to be taken in a limiting sense. The scope of the present invention is defined by the appended claims and their legal equivalents.

IN THE DRAWINGS

FIG. 1 is a schematic top plan view of a material moving apparatus described herein;

FIG. 2 is a schematic side elevational view of the material moving apparatus of FIG. 1;

FIG. 3 is a schematic cross sectional view of the material moving apparatus of FIG. 2 taken along line 3-3;

FIG. 4 is a schematic top plan view of a material moving apparatus with a discharge pipe described herein;

FIG. 5 is a schematic side elevational view of the material moving apparatus of FIG. 4;

FIG. 6 is a schematic showing a material moving apparatus operably connected to a downstream recepticle;

FIG. 7 is a schematic top plan view of a material moving apparatus with a check valve located downstream of the pumping chamber.

FIG. 8 is a schematic side elevational view of the material moving apparatus of FIG. 7;

FIG. 9 is a cross-sectional view of the material moving apparatus of FIG. 7 taken along line 9-9; and

FIGS. 10A and B are side-elevation views of the sealing chamber of the material moving apparatus showing a phantom valve in an open position and closed position.

While the invention is susceptible to various modifications and alternative forms, specifics thereof have been shown by way of example and drawings, and will be described in detail. It should be understood, however, that the invention is not limited to the particular embodiments described. On the contrary, the intention is to second modifications, equivalents, and alternatives falling within the spirit and scope of the invention.

DETAILED DESCRIPTION

The invention described herein provides a material moving apparatus suitable for transporting material from an ambient or high pressure environment to a low pressure or vacuum environment, without the transfer of unwanted air or gasses between the two environments. In particular, the invention provides a material moving apparatus that includes a chamber into which a compressible raw material is introduced. The chamber includes an input opening for receiving the material, a discharge opening and a sealing mechanism to prevent flow of air or other gasses between the input opening and the discharge opening. The invention provides a solution to a long-felt need in the gasification industry, namely, how to introduce biomass into a gasification reactor while preventing air and/or other unwanted gasses from entering the reactor.

Compressible Material

The material moving apparatus and method described herein can be used to transport a compressible material. As used herein, the term “compressible” refers to the tendency of a material to change its volume and density when subjected to pressure, for example, the volume of a compressible material can be reduced in response to applied pressure. In some materials, the compressible material retains its compressed shape, even after the pressure is removed or decreased. In some embodiments, the compressible material slowly expands after the pressure is removed or decreased.

In one embodiment, the material is compressed by application of a working pressure of at least about 5 psi and up to about 1000 psi, or of at least about 10 psi and up to about 200 psi, or between about 10 psi and about 50 psi.

In one embodiment, the compressible material includes a high solids material. As used herein, the term “high-solids material” includes dry and low moisture materials including materials having more than about 10%, 20%, 25%, 30%, 40%, 50%, 60%, 70%, 75%, 80% or 90% solids by weight. High solids materials are described in more detail in U.S. Patent Publication Number 2010/0278666, entitled “HIGH SOLIDS MATERIAL MOVING APPARATUS”, the disclosure of which is incorporated by reference in its entirety.

In a more particular embodiment, the compressible material includes biomass. As used herein, the term “biomass” refers to any carbon based material, and can include, but is not limited to, saw dust, yard trimmings, compost, wood chips, straw, grass, corn cobs, and corn stover. Other materials include garbage or waste material, including, but not limited to, bottles, cans, clothing, disposables, food packaging, and food scraps. Still other materials include paper materials, including, but not limited to, newspapers, magazines, cardboard, office paper, and paper bags. Other solid material can include plastics, including, but not limited to plastic bags, milk jugs and other storage containers. The biomass can also include mixtures and combinations of the materials listed herein or other similar materials.

The properties of each type of biomass can vary and thereby affect performance of the biomass as an energy source for a gasification plant. Some properties of the biomass that can affect performance include moisture content, ash content and ash composition, elemental composition, heating value, bulk density and morphology, volatile matter content and the presence of other fuel related contaminants such as N, S, Cl, alkalies, and heavy metals.

Material Moving Apparatus

FIGS. 1-5 show a material moving apparatus indicated generally at 10. In general, a material moving apparatus 10 includes a chamber 32 into which a compressible material is introduced. In one embodiment, the chamber 32 is a pumping chamber in which a plunger or ram 50 assembly is mounted for reciprocation along a longitudinal axis X-X. The ram 50 is configured to compress the material disposed within the chamber 32 and urge the compressed material out a discharge opening 40 of the chamber 32.

The chamber 32 can be any suitable size. The cross-sectional shape of the chamber 32 (i.e., perpendicular to the longitudinal axis X-X) can be any suitable shape, including circular, square, triangular, trapezoidal, rectangular, oval, and the like. In one embodiment, the cross-sectional shape of the chamber 32 is non-circular (i.e., is not a circle). In another embodiment, the chamber 32 has parallel side-walls, for example, a square or rectangular cross-sectional shape. In yet another embodiment, the chamber 32 has non-parallel side walls. In yet another embodiment, the chamber 32 has downwardly converging non-parallel side walls, where the sidewalls meet at a bottom surface or a point of the chamber 32. In the embodiment shown in FIG. 3, the non-parallel sidewalls 37, 38 are substantially planar and oriented in an upwardly open V-configuration that terminates in an apex at the base 36 of the apparatus 10. However, other converging configurations are known and can be used, including, for example, a downwardly converging chamber having curved sidewalls or a curved base is possible, for example, a chamber having a parabolic or inverted bell cross-sectional shape, or a pump having substantially planar non-parallel tapering sidewalls that terminate at a substantially planar base, thereby approximating a trapezoid in cross-section. In one embodiment (not shown), the sidewalls and base angles of the trapezoid are substantially the same and form an isosceles trapezoid. If desired, the material moving apparatus 10 can be mounted on support legs 11.

In one embodiment, the side walls 37, 38 define a chamber 32 that has a proximal (or upstream) end 44 defined by a rear wall 31 of the chamber 32 and a distal (or downstream) end 35 which defines a discharge opening 40. The sidewalls 37, 38 define an inlet opening 33 at the top of the chamber 32. In one embodiment, the inlet opening is located at the widest horizontal dimension of the chamber 32 to facilitate receipt of raw material from a collection hopper 20. In general, it is desirable to have a large inlet opening 33 for the chamber 32 to provide a wide feed point for the raw material. Downwardly converging sidewalls 37, 38 help funnel the material to the base 36 of the chamber 32. In the embodiment shown in FIG. 2, the inlet opening 33 of the chamber 32 is located at the proximal (or upstream) end 44 of the chamber 32. If desired, a top or cover 39 can enclose the distal (or downstream) end 34 of the chamber 32. The cover 39 can be removable for purposes of accessing the chamber 32 for cleaning or other maintenance. If desired the downstream end 34 of the chamber 32 can be tapered such that the portion proximate the discharge opening 40 has a cross-sectional area that is greater than a cross-sectional area of the chamber 32 located upstream. The increase in cross-sectional area can be as little as a fraction of a percent, for example as little as about 0.01% and up to about 10% over a distance of between about 10 inches to about 60 inches, 0.03% and up to about 10% over a distance of between about 10 inches to about 60 inches or as little as about 0.05% and up to to about 5% over a distance between about 10 inches to about 60 inches.

The invention described herein can be used in connection with any sized material moving apparatus, from small scale pumps having a pumping chamber size of no more than about 3 inches, no more than about 6 inches or no more than about 9 inches, to industrial sized pumps having sizes greater than about 11 inches, greater than about 16 inches, greater than about 20 inches, greater than about 24 inches, greater than about 30 inches or even greater than about 36 inches. In one embodiment, shown in FIG. 3, the cross sectional shape of the chamber 32 is a right triangle, wherein the right angle is located at the base 36 of the chamber 32. When referring to the “size” of a right triangle herein, the length of the hypotenuse is being discussed. Thus, when used in connection with the chamber 32, the term “size” refers to the length of the chamber cover 39 (e.g., the distance between the tops of the two sidewalls 37, 38). For chambers having other cross-sectional shapes, the term “size” can refer to the greatest distance between the sidewalls of the chamber, for example, the “size” of a semi-circular (or half circle) chamber would be the diameter of the circle.

The apparatus 10 can also include a hopper 20 for introduction of material into the chamber 32. The hopper 20 includes a hopper opening 21 defined by one or more hopper 20 sidewalls 22, 23, 24, 25 and is configured for contiguous relationship to and to be coextensive with the inlet opening 33 of the chamber 32 such that the high solids material is transferable from the inside of hopper 20 to the chamber 32.

In the embodiment shown in FIG. 2, the hopper 20 is configured to abut the inlet opening 33 of the chamber 32 at the proximal end 44 thereof. In the embodiment shown in FIG. 2, the rear wall 22 of the hopper 20 is substantially in vertical alignment with the rear wall 31 of the chamber 32.

The hopper 14 can be divided into two stages with an upper collection portion 26 and a lower passageway 27. In one embodiment, the upper collection portion 26 can include downwardly converging side walls extending from hopper opening 21 to the lower passageway 27. The lower passageway 27 can include side walls connected to and integrally extended from the lower edges of the respective sidewalls of the collection portion 26. In one embodiment, the sidewalls of the lower passageway 27 form a vertically extended passageway in which the horizontal dimensions of the passageway remain relatively constant through the vertical length thereof.

The apparatus 10 also includes a plunger or ram 50 assembly mounted for reciprocation in chamber 32. In general, the ram 50 is configured to substantially conform to the interior shape and dimensions of the chamber 32, allowing suitable clearance. In the embodiment shown in FIG. 1, the ram 50 is generally V-shaped, with downwardly converging side walls 52, 53 terminating in an apex 54. The ram 50 can include a forwardly directed face 51 to help efficiently move material through the chamber 32. In the embodiment shown in FIG. 1, the face 51 of the ram 50 is generally triangular in shape to confirm to the triangular shape of the chamber 32. The ram side walls 52, 53 are generally disposed in adjacent, close parallel relationship to the side walls 37, 38 of chamber 32. The ram top surface generally follows or is parallel to the inner surface of the cover 39 when working in the distal end 35 of chamber 32. In one embodiment, the ram side walls 52, 53 are in contact with the interior surface of the chamber.

Any suitable motor for reciprocation of ram 50 in chamber 32 can be used, including, mechanical, hydraulic, pneumatic, electrostatic and electrical motors. In one embodiment, the motor includes a double-acting hydraulic reciprocating motor that includes an elongate, hydraulic cylinder 55.

In use, raw material is placed into the chamber 32. The ram 50 advances in the chamber 32 (working stroke or power stroke) to push the high solids material towards the discharge opening 40. When the ram 50 reaches a first location (terminal position) within the chamber 32, the movement of the ram 50 is reversed in toward the rear of the chamber 32 (reverse stroke). When the ram 50 reaches a second location (retracted position), direction is again reversed to advance the ram 50 in the chamber 32 for reciprocal movement to the first location. If desired, the apparatus 10 can also include one or more pressure sensors capable of sensing pressure within the chamber 32.

In one embodiment, the material moving apparatus 10 includes a singular chamber that functions as both a pumping chamber 32 and a sealing chamber 132. For example, the terminal position of the ram 50 can be located upstream from the discharge opening 40 of the chamber, such that a “defacto” sealing chamber is formed. The term “sealing chamber” refers to a chamber in which raw material is compressed to form a substantially air-impermeable plug which functions to “seal” the downstream portion of the system (which can include a gasification reactor) off from the input opening 33 of the material moving apparatus 10 and prevent air or other gasses from the input opening 33 of the hopper 20 and/or pumping chamber 32 from traveling downstream of the compressed material. Essentially, the distal end 35 of the chamber 32 located downstream from the terminal position of the ram 50 can accumulate compressed material and thereby function as a sealing chamber. If desired, the distal end 35 of the chamber 32 can be tapered, such that the portion of the distal end 35 downstream from the terminal position of the ram 50 has a cross-sectional dimension that is greater than the cross-sectional dimension of the chamber 32 proximate the terminal position of the ram 50.

In another embodiment, such as is shown in FIGS. 7-9, the material moving apparatus 10 includes a sealing chamber 132 that is distinct from the pumping chamber 32. The sealing chamber 132 includes sidewalls 137, 138 that define a chamber 132 having a proximal (or upstream) end 144 and a distal (or downstream) end 135 which defines a discharge opening 140. As with the pumping chamber 32, the sealing chamber 132 can be any suitable size and have any suitable cross-sectional shape (i.e., perpendicular to the longitudinal axis X-X), including circular, square, triangular, trapezoidal, rectangular, oval, and the like.

It may be desirable to have a separate sealing chamber 132 that defines an enclosure with a different shape and/or size is than the enclosure defined by the pumping chamber 32 to prevent back-flow of the compressed material into the pumping chamber 32, inlet opening 33 and/or input hopper 20 of the material moving apparatus 10. For example, if the dimensions of the compacted material disposed within the sealing chamber 132 are greater than the dimensions of the material disposed within the pumping chamber 32, the compacted material will be less likely to backflow into the pumping chamber 32. Backflow of the material may be undesirable because it can result in deterioration of the seal formed by the compacted material that prevents the introduction of air and/or other gasses into the downstream receptacle, resulting in the introduction of unwanted gasses downstream. To reduce the likelihood of backflow, the sidewalls 37, 38 and/or cover 39 of the pumping chamber 32 can define a first enclosure having a first cross-sectional dimension and the sidewalls 137, 138 and/or cover 139 of the sealing chamber 132 can define a second enclosure with a second cross-sectional dimension, wherein a cross-sectional dimension of the second enclosure defined by the sidewalls 137, 138 and/or cover 139 of the sealing chamber 137 is greater than a cross-sectional dimension of the enclosure defined by the sidewalls 37, 38 and/or cover 39 of the pumping chamber 32. As used herein, the term “cross-sectional dimension” refers to a maximum corresponding distance between the sidewalls 137, 138 (or 37, 38) and/or between a sidewall 137, 138 (or 37, 38) and a cover 139 (or 39), when the cross-sectional shape of the two chambers is similar or identical. Similarly, if the cross-sectional shape of sealing chamber 132 is different than the cross-sectional shape of the pumping chamber 32, the likelihood that the compacted material will backflow into the pumping chamber is reduced. For example, the sidewalls 37, 38 and/or cover 39 of the pumping chamber 32 can define a first enclosure having a first cross sectional shape and the sidewalls 137, 138 and/or cover 139 of the sealing chamber 132 can define a second enclosure having a second cross-sectional shape, wherein the cross-sectional shape of the sealing chamber 132 is different than the cross-sectional shape of the pumping chamber 32. For example, the pumping chamber 32 may have a triangular cross-sectional shape, and the sealing chamber 132 may have a circular or rectangular cross sectional shape, the basic shape being consistent in each component. In yet another embodiment, the sealing chamber 132 is tapered such that the cross-sectional dimension proximate the upstream end 144 of the chamber 132 is smaller than the cross-sectional dimension proximate the downstream (or terminal) end 135 of the sealing chamber 137. The change in cross-sectional area can be as little as a fraction of a percent and ranges from 0.01% and up to about 10% over a distance of between about 10 inches to about 60 inches, 0.03% and up to about 10% over a distance of between about 10 inches to about 60 inches or as little as about 0.05% and up to to about 5% over a distance between about 10 inches to about 60 inches.

Valve

The material moving apparatus 10 includes a valve 150 located downstream of the discharge opening 140 of the sealing chamber 132. For the sake of brevity, the valve 150 will be described in connection with a material moving apparatus 10 that includes a separate sealing chamber 132. However, it is noted that the discussion can apply equally to a material moving apparatus 10 that includes a singular chamber 32 that functions both as a pumping chamber and a sealing chamber.

The valve 150 is located downstream of the sealing chamber 132. In one embodiment, the valve 150 is located at the terminal end 135 of the sealing chamber 132. The valve 150 is configured to prevent the material from exiting the sealing chamber 132 until the material is compacted sufficiently to render the compacted material substantially air-impermeable. Significantly, the compacted material that is accumulated in the sealing chamber 132 provides a seal or plug that impedes the passage of air (including, for example, oxygen) from the pumping chamber 32 to a downstream recepticle (for example, a discharge pipe 60 and/or gasification reactor 200).

Any suitable valve 150 can be used in connection with the material moving apparatus 10 described herein. As shown in FIGS. 10A and B, the valve 150 includes a valve plate 155 that has an upstream surface 151 and a downstream surface 152 and an open position (P_(o)) and a closed or restrictive position (P_(c)). When the valve 150 is in a closed position (P_(c)), the upstream surface 151 of the plate 155 is configured to provide an opposing surface positioned substantially perpendicular to the force exerted by the ram 50 (i.e., along the axis X-X) to compress the raw material. As the ram 50 pushes the raw material against the upstream surface 151 of the valve 150, the pressure exerted on the raw material, and hence the upstream surface 151 of the valve 150, increases. The pressure at which the valve 150 is configured to open can vary, but generally, the valve 150 is configured to open at a pressure of least about 5 psi and can withstand pressures of up to about 500 psi. In general, pressures between about 10 psi and 200 psi, or between about 10 psi and 50 psi are sufficient to compact the raw material to a density that renders the material substantially air-impermeable. As used herein, the term “substantially air impermeable” refers to a material through which air flow remains substantially undetected (i.e., using a sensor located downstream of the sealing chamber) when subjected to a vacuum pressure of at least 0.5 psi and up to about 5.0 psi. When the excess working pressure on the valve is relieved or when a pressure of below about 5 psi, or between about 1 psi and about 10 psi is detected, the valve returns to a restrictive position (P_(c)).

A variety of valves 150 can be used in connection with the material moving apparatus 10 described herein. In one embodiment, the valve 150 comprises a check valve that is configured to allow the compressed material to flow in only one direction (i.e., downstream) and prevent the material from flowing upstream. In another embodiment, the valve 150 is operably connected to a pump 175 which helps provide a counterbalancing force against the working force exerted by the ram 50 on the upstream surface 151 of the valve 150. Examples of suitable pumps include, but are not limited to, mechanical, hydraulic, pneumatic, electrostatic and electrical pumps.

A swing check valve is a check valve which has a plate that swings on a hinge or trunnion between an open and a closed position. One example of a swing check valves is a flapper valve.

As used herein, the term “flapper valve” refers to a valve 150 in which a valve plate 155 rotates around a hinge 160 to open and shut. In one embodiment, the flapper valve includes a spring-loaded plate 155 (or flapper) that allows materials to pass through in the downstream direction, but will not allow material to flow upstream. In one embodiment, the force at which the valve opens is dependent upon the torsion force of the spring. In another embodiment, the opening and closing of the valve is controlled by a pump 175, for example a mechanical pump or a hydraulic pump, in which case the material moving apparatus may include a pressure sensor within the sealing chamber 137 to determine when the valve should be opened or closed.

Other examples of check valves include lift-check valves and stop check valves and compression valves.

Gasification Reactor

In one embodiment, shown schematically in FIG. 6, the material moving apparatus 10 is operably connected to a downstream receptacle, for example, a discharge pipe 60 and/or a gasification reactor 200. In the embodiment shown, the material moving apparatus 10 includes a discharge pipe 60 downstream of the sealing chamber 132. In general, there are four types of gasification reactors available for commercial use: counter-current fixed bed, co-current fixed bed, fluidized bed and entrained flow. In some reaction processes, the gasification reactor is operated under a vacuum of at least about 0.5 psi and up to about 5 psi. The compressed material 350 formed within the sealing chamber 137 of the material moving apparatus 10 still functions as a seal to prevent entry of gas (including oxygen) into the downstream receptacle from the material moving apparatus 10. It is believed that throughput and efficiency of the gasification reaction can be increased, and waste material decreased, if the gasification process can be operated under a vacuum.

To further improve efficiency, it may be desired to reduce the average size of the raw material prior to placement within the input hopper 20 of the material moving apparatus 10, for example, using a shredder. The size of the shredded material can vary, for example, depending upon the size of the pump or the type of gasification reactor. In one embodiment, the material is shredded into pieces having a dimension that is less than about 10 inches, 5, inches, 2 inches or 1 inch. However, larger size pieces can still be used, as long as they can enter the pumping chamber and be compressed.

Discharge Pipe

As with the valve discussion above, the discharge pipe discussion herein will be written in connection with the distal end 135 of the sealing chamber 132. However, it is to be understood that the discussion would apply equally to a material moving apparatus 10 having a discharge pipe 60 extending directly from the distal end 35 of the pumping chamber 32. In one embodiment, the material moving apparatus 10 includes a discharge pipe 60 that extends downstream from the distal end 135 of the sealing chamber 132. The discharge pipe 60 includes a flange or other device configured to mate with a respective flange or device on the distal end 135 of the sealing chamber 132 such that the enclosure defined by the sidewalls 137, 138 and cover 139 of the sealing chamber 132 is in fluid communication with the lumen of the discharge pipe 60. Various configurations for the discharge pipe are possible and include, for example, configurations described in U.S. Patent Application Publication No. 2010/0278666, entitled “HIGH SOLIDS MATERIAL MOVING APPARATUS”, the disclosure of which is incorporated by reference herein in its entirety.

In Use

FIG. 6 provides a schematic of a material moving apparatus 10 in use. In use, loosely packed raw material 300 is transferred to collection hopper 20 of the pumping chamber 32. As the ram 50 advances from a rearward or refracted position, the ram 50 urges the raw material 300 into the sealing chamber 132. Upon retraction of the ram 50, additional raw material 300 can be transferred into the pumping chamber 32. As the raw material 300 is advanced by the ram 50 to the sealing chamber 132, the material is compacted by the working pressure exerted by the ram 50 as it pushes the material against the upstream surface 151 of the closed valve plate 155.

Once the material is compacted 350, the valve 150 moves to an open position and the compacted material 350 is released from the discharge opening 140 of the sealing chamber 32, for example, into a downstream receptacle, such as a discharge pipe 60 and/or a reaction chamber of a gasification reactor 200. The compacted material 350 forms a plug that impedes the flow of gas, for example air, more specifically oxygen, from the pumping chamber 32 into the downstream receptacle.

It should be noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.

It should also be noted that, as used in this specification and the appended claims, the phrase “configured” describes a system, apparatus, or other structure that is constructed or configured to perform a particular task or adopt a particular configuration. The phrase “configured” can be used interchangeably with other similar phrases such as “arranged”, “arranged and configured”, “constructed and arranged”, “constructed”, “manufactured and arranged”, and the like.

All publications and patent applications in this specification are indicative of the level of ordinary skill in the art to which this invention pertains. All publications and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated by reference.

This application is intended to cover adaptations or variations of the present subject matter. It is to be understood that the above description is intended to be illustrative, and not restrictive. It should be readily apparent that any one or more of the design features described herein may be used in any combination with any particular configuration. With use of a molding process, such design features can be incorporated without substantial additional manufacturing costs. That the number of combinations are too numerous to describe, and the present invention is not limited by or to any particular illustrative combination described herein. The scope of the present subject matter should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. 

1. A material moving apparatus comprising: (a) a chamber having an input opening located proximate an upstream end for receiving a compressible material and a discharge opening defined in a downstream end of the chamber; (b) a ram mounted in the chamber configured to compress the material and urge the compressed material out of the discharge opening of the chamber; and (c) a valve located downstream of the discharge opening configured to control movement of the compressed material out of the discharge opening of the chamber.
 2. The material moving apparatus of claim 1, wherein the ram has a retracted position and a terminal position such that the terminal position of the ram is located upstream of the downstream surface of the chamber thereby forming a sealing chamber in a downstream portion of the chamber for accumulation of compressed material.
 3. The material moving apparatus of claim 1, wherein the chamber comprises a pumping chamber and a sealing chamber.
 4. The material moving apparatus of claim 3, wherein the pumping chamber defines a first enclosure having a first cross-sectional dimension and the sealing chamber defines a second enclosure with a second cross-sectional dimension, wherein the cross-sectional dimension of the second enclosure defined by the sealing chamber is greater than the cross-sectional dimension of the pumping chamber
 5. The material moving apparatus of claim 3, wherein the pumping chamber defines a first enclosure having a first cross sectional shape and the sealing chamber defines a second enclosure having a second cross-sectional shape, wherein the cross-sectional shape of the sealing chamber is different than the cross-sectional shape of the pumping chamber.
 6. The material moving apparatus of claim 1, wherein the valve comprises a check valve.
 7. The material moving apparatus of claim 6, wherein the check valve has an open position and a closed position and the valve is configured to remain in the closed position until the compressed material is at a specified pressure whereupon the valve moves to the open position.
 8. The material moving apparatus of claim 7, wherein the check valve opens at a pressure of at least 5 psi.
 9. The material moving apparatus of claim 7, wherein the check valve opens at a pressure between about 10 psi and about 1000 psi.
 10. The material moving apparatus of claim 6, wherein the check valve comprises a flap valve.
 11. The material moving apparatus of claim 1, further comprising a discharge pipe operably connecting the material moving apparatus to a gasification reactor.
 12. The material moving apparatus of claim 1, wherein the compressible material comprises biomass.
 13. The material moving apparatus of claim 1, wherein the compressible material is selected from the group consisting of: bio-solids, including, saw dust, yard trimmings, compost, wood chips, straw, grass, corn cobs, and corn stover; garbage or waste material, including, bottles, cans, clothing, disposables, food packaging, and food scraps; paper materials, including, newspapers, magazines, cardboard, office paper, and paper bags; plastic materials, including milk jugs and other storage containers; and mixtures and combinations thereof.
 14. A method for moving a compressible material, the method comprising: (a) placing a compressible material in a chamber having an input opening for receiving the compressible material and a discharge opening; (b) compressing the material to form a compressed material; (c) controlling the compression of the material using a valve located downstream of the discharge opening; and (d) pumping the compressed material out of the discharge opening of the chamber.
 15. The method of claim 14, further comprising: pumping the compressed material out of the discharge opening of the chamber into a discharge pipe, wherein the discharge pipe operably connects the material moving apparatus to a gasification reactor.
 16. The method of claim 15, further comprising: compressing the material under a pressure sufficient to form a compressed material that is air-impermeable.
 17. The method of claim 16, wherein the material is compressed under a pressure of at least about 5 psi.
 18. The method of claim 14, further comprising: transporting the compressed biomass to a downstream receptacle.
 19. The method of claim 18, wherein the downstream receptacle comprises a discharge pipe, a gasification reactor, or a combination thereof.
 20. The method of claim 19, wherein the gasification reactor is operated under a vacuum of between about 0.5 psi to about 5 psi. 